Section of side panel, rear sill: Fitting

Fig 1: Illustration For Step 5

Courtesy of SAAB-SCANIA OF AMERICA, INC.

1. Drill holes in the reinforcement for plug-welding.
2. Grind clean the surfaces that are to be welded on the body and reinforcement.
3. Apply welding primer to the surfaces that are to be plug welded. Use Terosan Zinkspray.
4. Fit the reinforcement and fixate with a couple of welding clamps.
5. Plug-weld the reinforcement.
6. Roughly cut the new side panel so that it will overlap the joint by three centimeters.
7. Position the side panel on the body and cut it together with the existing panel so that the joint can be welded edge-to-edge.
8. Drill holes on the bottom edge for plug-welding.
9. Grind clean the surfaces that are to be welded.
10. Apply welding primer to the surfaces that are to be plug and spot-welded. Use Terosan Zincspray.
11. Position the side panel and fix it with a few welding clamps.
12. Plug and spot-weld it.
    Fig 2: Illustration For Step 12-13

    Courtesy of SAAB-SCANIA OF AMERICA, INC.
13. All-weld the joint.
14. Smooth off the welds.
15. Remove any remaining welding primer. Welding primer reduces adhesion of paint, filler and sealant.
16. Apply primer to all bare metal surfaces.
17. Seal joints and seams with sealant.
18. Apply anti-corrosion agent to the interior of the side panel. Use Terotex HV 400 or Mercasol 1.